Thermocalendered non-woven laminate

ABSTRACT

An elastic laminate fabric useful for applications including apparel, sanitary products, and the like has an elastic vinylidene isoprene polymer film sandwiched between two outer non-woven layers. The laminate elastic fabric has CD elongation of at least 120%, and has recovery of at least 85% after several cycles of 100% elongation. A method of making the non-woven elastic laminate fabric includes extrusion coating a non-woven web having CD elongation of at least 120% with a vinylidene isoprene polymer film, and then thermocalendaring a second non-woven layer having a CD elongation of at least 120% to the exposed film surface. The mode of thermocalendering includes the use of an engraved calender roll having a discontinuous roll pattern and a land area no greater than 15%.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This is a continuation-in-part of application Ser. No.09/370,344, filed Aug. 6, 1999.

BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to laminate elasticfabrics, and more particularly to elastic fabrics that are comprised ofa non-woven layer laminated to an elastic layer, the laminate beingformed by a controlled combination of temperature and pressure to renderthe laminate with a specific elastic performance.

[0003] The prior art contains a number of examples of laminate elasticfabrics comprised of a non-woven layer and an elastic layer. Suchfabrics are useful for applications such as garments, disposable medicalproducts, personal hygiene products, industrial products, and diapers.Depending on the particular application, the fabric may requireparticular properties such as a desired degree of elongation/recovery,porosity, softness, etc. These properties may be influenced by theselection of the particular non-woven component layer and the elasticcomponent layer.

[0004] To construct the non-woven laminate elastic, the non-woven layermay be laminated to the elastic component layer with a chemical bond,mechanical bond, or by thermal bonding. Tension may be applied to eitherthe elastic member or the non-elastic member prior to laminating toprovide the final fabric with its elastic elongation capability. Inthese various methods of fabrication, the recovery capability of thelaminate is a function only of the recovery of the elastic member.

[0005] When the elastic layer is stretched prior to joining the layers,the non-woven layer then “gathers” between the bond points when thelaminate is relaxed, with the laminate surface disadvantageously showing“puckering”. Also, this method of fabricating an elastic laminateresults in only a limited elongation potential, as an effect called“positive stop” limits laminate extension to the physical limits of thenon-woven gathered between the bonded points. Such a process isdisclosed in U.S. Pat. No. 4,720,415, and U.S. Pat. No. 4,842,596,incorporated herein by reference.

[0006] Alternatively, the non-woven layer can be tensioned prior tojoining a tensioned or relaxed elastic member. When relaxed, thelaminate fabric again shows a puckered surface with “gathers” of thenon-woven between bond points. The previously described “positive stop”feature is also again manifested by the extension of the gathers in thenon-woven layer when tension is applied. Also, this method produces adimensional distortion in the non-woven layer referred to as “necking”or “necking in”. Several variations of this process are disclosed inU.S. Pat. Nos. 4,981,747; No. 5,226,992; No. 5,336,545; and No.5,514,470; incorporated herein by reference.

[0007] These methods produce laminates that exhibit stretch and recoveryprimarily oriented in the direction of the applied tension, the machinedirection (“MD”). Little or no stretch and recovery is induced in thecross tension direction (“CD”). Achieving a degree of elastic stretchand recovery in the CD has been significantly more difficult than theMD.

[0008] U.S. Pat. No. 5,114,781, incorporated herein by reference,discloses a method for producing a laminate, which has CD elasticstretch and recovery. The process disclosed is based on laminating a‘reversibly necked’ substrate under tension to a tensioned elasticmember. The provided definition of a ‘reversibly necked’ fabric is onethat has been treated in some way while in a tensioned, necked-in stateto impart memory to the material. The effect of this memory is to inducethe fabric to return to its necked-in configuration after tension isapplied in the CD. The fabric and method disclosed, however, result in afabric surface that is puckered and gathered as the necked-in fabric isbonded to a tensioned elastic layer. Also, the reversible necking of thenon-elastic layer requires an additional process step with associatedcosts and efforts.

[0009] Thus it is made apparent that the tensioning processes generallydisclosed in the prior art have associated shortcomings. The practicehas resulted in fabrics generally having only MD elasticity, at theexpense of elasticity in the CD. Among other factors, this has resultedfrom the requirement of tensioning either the elastic or non-elasticlayers or both when the layers are bonded together. While significanttensioning may be achieved in the MD, it is much more difficult toachieve in the CD, particularly simultaneously with the MD tensioning asMD tensioning in the MD may cause the CD dimension to be reduced or“necked in”, and to thereby lose CD elongation capacity.

[0010] Further, tensioning results in fabrics having a disadvantageouslygathered or puckered surface, and limited elongation. Equipment andprocess controls are required for tensioning that are far more complex,expensive, and difficult to maintain than a standard laminationprocessing line. Finally, the fabrics of the prior art have offered onlylimited elastic recovery, particularly after multiple elongation cycles.

[0011] A heretofore unresolved need therefore exists for an improvedprocess for making an elastic laminate non-woven fabric, and likewisefor an improved elastic laminate non-woven fabric.

OBJECTS OF THE INVENTION

[0012] It is an object of the invention to provide a process for makinga non-woven elastic laminate fabric having a high degree of CDelongation.

[0013] It is a further object of the invention to provide a process formaking a non-woven elastic laminate fabric having a high degree ofelastic recovery, the laminate being formed by a controlled combinationof temperature and pressure to render the laminate with a specificelastic performance.

[0014] It is a further object of the invention to provide a non-wovenelastic laminate fabric having a high degree of CD elongation.

[0015] It is a still further object of the invention to provide anon-woven elastic laminate fabric having a high degree of elasticrecovery, the laminate being formed by a controlled combination oftemperature and pressure to render the laminate with a specific elasticperformance.

SUMMARY OF THE INVENTION

[0016] The present invention comprises a method for making a non-wovenelastic laminate fabric, as well as the elastic laminate fabric producedthereby, the laminate being formed by a controlled combination oftemperature and pressure to render the laminate with a specific elasticperformance.

[0017] The elastic non-woven laminate fabric of the invention comprisesa non-woven fabric web having a CD elongation of at least 120% and abasis weight of between about 10-100 gm/m² laminated to an elastic filmlayer comprised of a vinylidene isoprene polymer having a thickness ofbetween 0.5 to 3.5 mils. The resulting elastic laminate non-woven fabricof the invention has CD elongation of at least 120%, MD elongation of25-70%, and a CD elastic recovery of at least 85% after multiple cyclesof 100% elongation.

[0018] It is noted that % elongation as used herein may be defined as:${{elongation}\quad \%} = {100 \times \left\lbrack \left( \frac{{{elongation} \cdot {length}} - {{original} \cdot {length}}}{{original} \cdot {length}} \right) \right\rbrack}$

[0019] Thus if a fabric is 10 in. long in a relaxed original state, andmay be stretched to 25 in, then it shows 150% elongation. Further, asused herein % recovery may be defined as:${{recovery}\quad \%} = {100 \times \left\lbrack \left( \frac{{{elongated} \cdot {length}} - {{final}\text{/}{{relaxed} \cdot {length}}}}{{{elongated} \cdot {length}} - {{original} \cdot {length}}} \right) \right\rbrack}$

[0020] Thus if the above fabric returned to a relaxed final state of 15in., then it shows 67% recovery.

[0021] Preferably, the non-woven web component of the fabric of theinvention has a CD elongation of at least 150% and a basis weight ofbetween about 15-50 gm/m². The preferred non-woven web may comprisespunbond or meltblown filament webs, or hydroentangled, carded staplefibers. Preferred materials of composition for the non-woven web of theinvention include poly(ethylene terephthalate) (“PET”) and polyolefins.

[0022] The use of the preferred film also provides advantages over theuse of elastic net-like structures or reticulated films in that moreuniform elongation and a more uniform, wrinkle free surface appearanceresult. The film is preferably extrusion coated onto the non-woven web,while the web is in a relaxed, un-tensioned state (except for tensioningas may be required for normal web processing). The preferred extrusioncoating of the film onto the non-woven web results in a final fabrichaving a smooth, ungathered or puckered surface, as all components arejoined in an effectively relaxed configuration. Further, extrusioncoating provides for large bonding interface area between layers, sothat a coherent final laminate fabric results. Other means of attachmentcomprise bonding with an adhesive or thermal bonding by calendering.

[0023] The fabric of the invention has a CD elongation of at least 120%and preferably greater than 150% that is superior to that of elasticnon-woven laminates of the prior art. Further, the elastic recovery ofthe fabric of the invention, which is 85% or greater after severalcycles of 100% elongation, is also superior to that of any prior artelastic non-woven laminate fabric.

[0024] A preferred embodiment of the laminate elastic fabric of theinvention comprises an elastic layer sandwiched in between two non-wovenouter layers. A first non-woven web is as described above, with a CDelongation of at least 120%, with at least 150% most preferred, and abasis weight of between about 10-50 gm/m². An elastic vinylideneisoprene film, with a thickness of between about 0.5-3.5 mils, islaminated onto the web. Finally, a second non-woven web having a CDelongation of at least 120% as well as other physical properties andcharacteristics that may be substantially similar to the first web,including basis weight, is thermally bonded to the exposed side of thefilm with the film thereby sandwiched between the two non-woven layers.The temperature and pressure used to perform the lamination having apronounced effect on physical performance.

[0025] The method of the invention generally comprises the steps ofproviding a non-woven fabric web having a CD elongation of at least 120%and a basis weight of between 10-50 gm/m², attaching an elastic film tothe non-woven web with both the web and the film in substantiallyrelaxed, unstretched states. The film comprises a vinylidene isoprenepolymer with a thickness of between about 0.5 and 3.5 mils. Thepreferred means of attachment of the film to the non-woven web is byextrusion coating. As both the elastic and non-woven layers are insubstantially relaxed, unstretched states when joined, the finallaminate fabric of the invention has a smooth surface free from thepuckering and/or gathering of non-woven elastic laminates of the priorart.

[0026] The preferred non-woven web provided in the method of theinvention is as generally described above in relation to the preferredfabric of the invention. It has a CD elongation of at least 150% and abasis weight of between about 10-100 gm/m². The web may comprisespunbond or meltblown continuous filaments, or more preferablyhydroentangled, or highly randomized, carded staple fiber webs. The webmay be prepared in line with the joining of the layers, or may beprepared separately. Preferred materials of composition includepolyolefins, and polyesters (PET), polyamides, and the blends thereof.

[0027] The preferred vinylidene isoprene polymer film of the method ofthe invention is also as described above in association with thepreferred fabric of the invention. Most preferably the film has athickness in range of about 2.0 to 2.5 mils.

[0028] A preferred embodiment of the method of the invention comprisesthe steps of providing a first non-woven web having a CD elongation ofat least 120%, with at least 150% most preferred, and a basis weight ofbetween about 10-50 gm/m². Next, an elastic vinylidene isoprene film isextrusion coated onto the web in a thickness as described above,including preferred ranges. A second non-woven web having physicalproperties and characteristics similar to the first web, including basisweight and CD elongation, is then thermally bonded to the exposed sideof the film with both the second web and the first web and film laminatein substantially relaxed, unstretched states. The film is therebysandwiched between the two non-woven layers.

[0029] The thermal point bonding of the second layer to the exposed sideof the film can be carried out at a temperature in the range of themelting temperature of the film, to result in an intimate co-mingledbond between both outer non-woven layers and the film layertherebetween.

[0030] It has been found that subtle variations in the bondingtemperature and pressure during the lamination process yield constructsof differing performance. Two particularly preferred sets of bondingtemperatures and pressures are referred to those yielding a “high-bond”and a “low-bond”. Both high-bond and low-bond materials are formed bythe application of an engraved calender roll having a discontinuous bondpattern with no greater than about 15% land area. The high bondmaterials incorporate the use of the engraved calender roll at atemperature in the range of about 360° F. to 390° F. The low-bondmaterials incorporate the use of the engraved calender roll at atemperature in the range of about 340° F. to 360° F. The pressure of theengraved calender roll for the manufacture of the high-bond materialversus the low-bond is increased by no more than about 10%.

[0031] An optional, additional step in the method of the inventionfurther comprises tensioning the laminated fabric of the invention inthe machine direction after joining of the layers in a calender nip andbefore winding the fabric onto a winder. The tension is released beforewinding, so that the fabric is wound in a relaxed state. The tensioningcauses some bonds to break in the nonwoven fabric layers. This breakageincreases the overall elongation capacity of the laminate fabric, anddecreases the stretch force of the laminate fabric.

[0032] The method of the invention thereby provides an improved processfor making an elastic non-woven laminate fabric that does not requireapplying unusual tension to or otherwise stretching either the non-wovenlayer(s) or the elastic layer, instead allowing fabrication while thelayers are in a substantially relaxed, un-extended state. The presentinvention therefore avoids the additional efforts and expensesassociated with the stretching of one or all of the layers duringprocessing, specifically the specialized equipment and process controlsrequired to provide and maintain a tensioning station in the productionline.

[0033] Further, the method of the invention is a simpler and moreefficient method than those of the prior art. Also, the method of theinvention results in a fabric having CD elongation of at least 120%, andelastic recovery of at least 85% after 3 cycles of 100% elongation.

[0034] The above brief description sets forth rather broadly the moreimportant features of the present disclosure so that the detaileddescription and examples that follow may be better understood, and sothat the present contributions to the art may be better appreciated.There are, of course, additional features of the disclosure that will bedescribed hereinafter which will form the subject matter of the claimsappended hereto. In this respect, before explaining the severalembodiments of the disclosure in detail, it is to be understood that thedisclosure is not limited in its application to the details of theconstruction and the arrangements set forth in the following descriptionor illustrated in the drawings. The present invention is capable ofother embodiments and of being practiced and carried out in variousways, as will be appreciated by those skilled in the art. Also, it is tobe understood that the phraseology and terminology employed herein arefor description and not limitation.

BRIEF DESCRIPTION OF THE FIGURES

[0035]FIG. 1 shows a schematic diagram of the preferred method of theinvention;

[0036]FIG. 2 shows a cross section view of the preferred fabric of theinvention; and

[0037]FIG. 3 is a plan view of a disposable absorbent article,illustrated as a disposable diaper, embodying the present invention.

DETAILED DESCRIPTION AND EXAMPLES

[0038] Turning now to FIG. 1, a schematic of the preferred method ofmaking a laminated non-woven elastic fabric is shown. A first non-wovenlayer 2 having a CD elongation of at least 120%, and more preferably150%, is unwound from roller 4. Non-woven 2 has a MD elongation in therange of 25-70%, with 25-45% most common. In general, the lower theMD/CD elongation ratio, the higher the CD elongation; i.e. the more CDorientation of the fibers/filaments, the greater the CD elongation.Non-woven layer 2 may comprise spunbond or meltblown filament webs, orhydroentangled or carded staple fibers webs, such as highly randomizedcarded staple fiber webs. Hydroentangled webs and highly randomized,carded webs that are adhesive or thermal bonded are preferred.

[0039] Preferred materials of composition for web 2 are polyolefins andPET. A preferred basis weight for web 2 is between about 10-100 gm/m²,with 15-50 gm/m² most preferred. Table 1 lists some examples of suitablenon-woven substrates layers and associated CD tensile characteristicsthat may be used in the method and fabric of the invention (thenon-woven substrates of the invention are not limited to the examples ofTable 1).

[0040] Elastic film 6 comprised of a vinylidene isoprene polymer havinga thickness of between 0.5 to 3.5 mils is extrusion coated ontonon-woven web 4 by extruder 8, while both film 6 and web 2 are insubstantially relaxed, unstretched states, except that web 2 is undernormal tension as may be required to unwind and to otherwise process it.

[0041] The preferred vinylidene isoprene polymer film 6 of the fabric ofthe invention has a thickness of about 2 mils, and comprises 70-95% of ablock copolymer with the general formula A-B-R-(B-A)_(n) where A is amonovinylidene aromatic monomer, B is a conjugated diene, R is a remnantof a multifunctional coupling agent, and n is an integer from 1-5. Asecond preferred film composition comprises 70-95% of a block copolymerwith the general formula A_(x)-(BA)_(Y)-BA where A is a monovinylidenearomatic monomer, B is a conjugated diene, x is from 0-1, and y is from0-3. A commercial version of the preferred film is available under theVECTOR tradename from the Dexco Corp., a Dow Chemical, Exxon Chemicaljoint venture in Plaquemine, La.

[0042] Second non-woven layer 10 is next unwound from roller 12 anddeposited on the exposed side of film 6. Non-woven web 10 is depositedin a substantially relaxed, unstretched state to a likewise un-tensionedweb 2/film 6 laminate. That is, the three layers are not tensioned,stretched, necked, elongated, or otherwise subjected to additionaltensioning at the time they are joined together beyond that required bythe process to maintain alignment of the fabrics through the process(this is the general meaning intended to be applied throughout thisapplication to the general description of “being substantially relaxedand un-tensioned”). The resultant fabric of the invention therebyadvantageously has a surface that is not wrinkled, bunched, or gathered.

[0043] The novel method of attachment of the elastic film to thenon-woven layer of the invention with both layers in substantiallyun-tensioned, relaxed states further provides the fabric of theinvention with greater CD elongation and recovery capacities thanfabrics of the prior art. The principal methods of the prior art rely onapplying excessive tension in the MD during the consolidation of thelaminates. When it is the elastic member that is tensioned in thismanner, very little CD elongation capacity remains, and the structure islocked in this configuration during the bonding step. When it is thenon-woven layers that are “necked in” or tensioned, only limited CDelongation results contributed entirely by the amount of fabric in thegathers and limited to those gathered fabric dimensions when the gathersare pulled out.

[0044] Non-woven layer 10 may have substantially the same physicalcharacteristics as first non-woven layer 2, and likewise may becomprised of the same materials. On the other hand, non-woven layer 10may have different physical properties from first non-woven layer 2, orbe comprised of different materials, as may be desired. It is critical,however, that the second non-woven layer 10 has a CD elongation of atleast 120%, and preferably of at least 150%. Table 1 above is referredto for examples of suitable webs for comprising non-woven layer 10.

[0045] Heated, engraved, calender rolls 14 thermally bond secondnon-woven layer 10, film 6, and first non-woven layer 2. Thus film 6 issandwiched between outer non-woven web layers 2 and 10. Preferably,calender rollers 14 operate at a temperature in the melting range offilm 6 so that an integral bond results between all three layers, withfibers or filaments in the outer nonwoven layers thereby intermingledwith the film layer at the bond point. Film 6 is actually observed tothin at the bond points.

[0046] In the preferred embodiment of the method of the invention asdepicted in FIG. 1, after calendering with calender rollers 14, thelaminated fabric 16 of the invention is tensioned in the MD with tensionrollers 18. Tensioning in the MD breaks some of the fibers in the outernon-woven layers, leading to increased MD elongation and decreasedstretch force in fabric 16, as well as generally improved hand. Tensionin fabric 16 is released after passing tension rollers 18, and laminatedelastic fabric 16 is finally wound on roller 20 in a substantiallyrelaxed, un-stretched state.

[0047]FIG. 2 is a cross section of a preferred fabric 16 of theinvention, as produced by the preferred process described above. Fabric16 comprises outer non-woven layers 2 and 10 sandwiching elastic filmlayer 6. Non-woven outer layers 2 and 10 must have a CD elongation of atleast 120%, and preferably of at least 150%. They preferably have abasis weight in the range of 15-50 gm/m², and may comprise spunbond ormeltblown continuous filaments, or hydroentangled, carded, highlyrandomized staple fibers. Preferred materials of composition comprisepolyolefins, polyesters, polyamides, and the combinations thereof.Reference is made to Table 1 above for examples of suitable non-wovenlayers. As illustrated in FIG. 2, the preferred fabric of the inventionhas a surface that is substantially flat and is not bunched, gathered,or necked in. This results from the outer nonwoven web layers 2 and 10being in substantially unstretched, relaxed states when attached to filmlayer 6.

[0048] Preferred elastic film 6 is the VECTOR film as described above,available from the Dexco Corp., in Plaquiemine, La.; with a preferredthickness of between about 0.5 and 3.5 mils, with a most preferredthickness in the range of about 2.0 to 2.5 mils. Preferably, film 6 isextrusion coated onto first non-woven layer 2, with non-woven layers 2and 10 and film layer 6 then thermally point bonded together at atemperature in the melting range of film 6 to achieve an integral bondbetween all three layers.

[0049] The preferred laminate fabric of the invention has a CDelasticity of at least 120% and most preferably greater than 150% thatis superior to that of elastic non-woven laminates of the prior art.Further, the CD elastic recovery of the fabric of the invention, whichis 85% or greater after several cycles of 100% elongation, is alsosuperior to that of prior art elastic non-woven laminate fabrics. It isnoted that the nature of the non-woven layers significantly affects therecovery of the laminate fabric. Non-woven fabrics show hysteresisrecovery when cycled to limits below their yield point. The higher theoverall elongation of the non-woven, the more recovery power the fabricwill be able to contribute to the laminate recovery. So, a laminate madewith a non-woven substrate having 120% elongation would be expected toprovide a lower elastic recovery from a 100% extension than a laminateprepared with a substrate having 175% elongation.

[0050] A comparison between several elastic laminate fabrics of theinvention and prior art elastic laminate fabrics is provided in Table 2.The “Comparative Examples” in Table 2 are elastic laminate fabrics thatare commercially available, where “SB” is spunbond, “PP” ispolypropylene, and “PE” is polyethylene. “Elastic Film” of Table 2 is anextruded film of the described VECTOR film polymer. The “ElasticLaminates” of Table 2 identify several fabrics of the invention preparedaccording to the method of the invention, where “HEF” indicateshydroentangled fabric, and “PET” is poly(ethylene terephthalate). The“Tensioned Fabrics” of Table 2 indicate fabrics that have been tensionedas described above (at 18 in FIG. 1) after lamination.

[0051] Table 2 illustrates the superior recovery of the fabrics of theinvention over prior art fabrics. Table 2 also shows the reduced elasticforce of the fabrics of the invention over prior art fabrics. Thus thefabrics of the invention combine increased recovery with reduced elasticforce over prior art fabrics, which is a surprising result of the fabricand method of the invention as typically increased recovery is onlyachieved through increased elastic force. The fabrics of the inventionare able to achieve a relatively gentle retractive force through theirunique method of fabrication; and particularly due to the use of thevinylidene isoprene film of the invention.

[0052] The high level of recovery after multiple extensions that thefabrics of the invention show is a result of their unique design.Because the laminated layers are joined without application of tension,there is no initial introduction of stress during formation tostructurally deform the non-elastic members or to reduce the elasticityof the elastic member. As the non-elastic member is not under excessivetension during manufacture of the laminate, the natural recovery of thehigh elongation fabric is able to contribute to the recovery performanceof the final laminate fabric.

[0053] Table 3 illustrates the advantageous effects subtle variations intemperature and pressure have on the performance of the laminateconstruct manufactured in accordance with the present invention. Initialconstructs were formed from the combination of two outer layers ofextensible 26.5 gram per square meter HEF PET fabric and an elasticinner vinylidene isoprene film layer at a thickness about 3.5 mil. Theconstructs where then individually laminated at the low-bond andhigh-bond conditions as indicated. As can be seen from the physicalproperty testing, stretch and recovery performance and tear strength canbe tuned utilizing alteration of bond temperature and pressure.

[0054] A number of end-use articles can be benefit from the inclusion orsubstitution of an elastic material layer with the elastic laminate ofthe present invention, including, but not limited to, hygiene absorbentarticles, such as diapers and catamenial products, andmedical/industrial protective articles.

[0055] Disposable waste-containment garments, are generally described inU.S. Pat. No. 4,573,986, No. 5,843,056, and No. 6,198,018, which areincorporated herein by reference.

[0056] An absorbent article incorporating a vinylidene/nonwoven elasticlaminate of the present invention is represented by the unitarydisposable absorbent article, diaper 20, shown in FIG. 3. As usedherein, the term “diaper” refers to an absorbent article generally wornby infants and incontinent persons that is worn about the lower torso ofthe wearer. It should be understood, however, that the present inventionis also applicable to other absorbent articles such as incontinencebriefs, incontinence undergarments, diaper holders and liners, femininehygiene garments, training pants, pull-on garments, and the like.

[0057]FIG. 3 is a plan view of a diaper 20 in an uncontracted state(i.e., with elastic induced contraction pulled out) with portions of thestructure being cut-away to more clearly show the construction of thediaper 20. As shown in FIG. 3, the diaper 20 preferably comprises acontainment assembly 22 comprising a liquid pervious topsheet 24; aliquid impervious backsheet 26 joined to the topsheet; and an absorbentcore 28 positioned between the topsheet 24 and the backsheet 26. Theabsorbent core 28 has a pair of opposing longitudinal edges, an innersurface and an outer surface. The diaper can further comprise elasticleg features 32; elastic waist features 34; and a fastening system 36which preferably comprises a pair of securement members 37 and a landingmember 38.

[0058] Practical application of an elastic laminate, and preferably astrong, highly elongateable fabric, as the primary constituent in theelastic leg features 32, elastic waist feature 34, and securement member37 results in a diaper that is more flexible and therefore moreconforming to deformation of the overall structure as the diaper isworn. Further, as the backsheet is subjected to frictional contact withthe user's environment, the absence of pleats, corrugations, or othersurface variances aid in ensuring that the overall diaper construct doesnot fail structurally while the diaper is in use.

[0059] Medical and industrial protective products, such as medical gown,surgical drape and oversuits can benefit significantly from theinclusion of the elastic laminate of the present invention. Ofparticular utility in the fabrication of such protective products is theapplication of the elastic laminate in cuff areas, neck regions, andfitments whereby the recoverable elongation and strength attributeimproves product performance and wearer comfort. Patents generallydescribing such protective products include U.S. Pat. No. 4,845,779, No.4,876,746, No. 5,655,374, No. 6,029,274, and No. 6,103,647, which areincorporated herein by reference.

[0060] The advantages of the disclosed invention are thus attained in aneconomical, practical, and facile manner. While preferred embodimentsand example configurations have been shown and described, it is to beunderstood that various further modifications and additionalconfigurations will be apparent to those skilled in the art. It isintended that the specific embodiments and configurations hereindisclosed are illustrative of the preferred and best modes forpracticing the invention, and should not be interpreted as limitationson the scope of the invention as defined by the appended claims. TABLE 1Fabric CD CD Basis Wt. Tensile Elongation Sample (gm/m²) (gm) (%) CardedPP staple fiber 40 645 151 Hydroentangled PET staple fiber 24 128 222Apertured hydroentangled PET staple 31 710 152 fiber Hydroentangled PETstaple fiber 57 1,772 104

[0061] TABLE 2 % Elastic Recovery Fabric Basis Elastic Force (gm) @ 100%after 3^(rd) Weight CD Elongation 100% CD Fabric (gm/m²) Cycle 1 Cycle 2Cycle 3 Cycle Comparative Examples (prior art): SB-PP 138 1,021 998 82875 SB-PE with Film 105 705 658 637 81 SB-PP with Film 98 1,615 1,3881,306 80 Film alone 59 272 249 249 94 Elastic Laminates of theInvention: HEF-PET with 111 892 650 544 88 Film HEF-PET with 117 514 431393 91 Film Carded PP with 140 665 575 529 89 Film Tensioned Fabrics ofthe Invention: Carded PP with 145 416 386 363 89 Film Carded PP with 165302 272 265 90 Film

[0062] TABLE 3 Elastic Force (gm) % Elastic Bond @ 100% CD ElongationRecovery Tear Basis Bond Pressure Cycle Cycle Cycle after 3^(rd)Strength Material Weight Temp (° F.) (psi) 1 2 3 CD Cycle (g/in) 3.5 mil144 30− 65 740 600 534 88 2800 High Bond 3.5 mil 145 360 60 322 289 26692 897 Low Bond

What is claimed is:
 1. A method of making a laminate elastic fabric,comprising the steps of: a) providing a first and second nonwoven fabricweb comprised of thermoplastic polymers having a CD elongation of atleast 120%; b) providing an elastic film comprised of a vinylideneisoprene polymer having a thickness of between about 0.5 and 3.5 mils;c) positioning said elastic film between said first and second nonwovenwebs, in face to face juxtaposition, said first and second nonwoven websand said film being in substantially relaxed, untensioned states; and d)applying elevated temperature to affix said nonwoven webs to said film,said elevated temperature provided by contact with an engraved calenderroll having a discontinuous bond pattern of no greater than 15% landarea.
 2. A method of making an elastic fabric as in claim 1, whereinsaid attaching of said first non-woven web to said elastic filmcomprises extrusion coating said elastic film onto said web.
 3. A methodof making an elastic fabric as in claim 1, wherein said non-woven fabricweb has a CD elongation of at least 150%.
 4. A method of making anelastic fabric as in claim 1, wherein said non-woven web comprises amember chosen from the group consisting of spunbond continuousfilaments, meltblown continuous filaments, hydroentangled carded staplefibers, thermally bonded carded staple fibers, and adhesively bondedcarded staple fibers.
 5. A method of making an elastic fabric as inclaim 1, wherein said vinylidene isoprene film comprises 70-95% of ablock copolymer with the general formula chosen from the groupconsisting of: A-B-R-(B-A)_(n) where A is a monovinylidene aromaticmonomer, B is a conjugated diene, R is a remnant of a multifunctionalcoupling agent, and n is an integer from 1-5; and A_(x)-(BA)_(y)-BAwhere A is a monovinylidene aromatic monomer, B is a conjugated diene, xis from 0-1, and y is from 0-3.
 6. A method of making an elastic fabricas in claim 1, wherein said vinylidene isoprene film has a thickness inthe range of about 2.0 to 2.5 mils.
 7. A method of making an elasticfabric as in claim 1, further comprising the steps of providing a secondnon-woven fabric web comprised of thermoplastic polymers, and attachingsaid second non-woven fabric web to said elastic film.
 8. A method ofmaking an elastic fabric as in claim 7, wherein said second non-wovenweb is calendered to said film at a temperature in the range of the filmmelting point.
 9. A method of making an elastic fabric as in claim 1,wherein said non-woven web has a basis weight between about 10-100gm/m².
 10. A method of making an elastic fabric as in claim 1, whereinsaid non-woven web has a basis weight between about 15-50 gm/m².
 11. Amethod of making an elastic film as in claim 1, further comprising thestep of tensioning the laminated fabric in the machine direction afterattaching said non-woven layer to said elastic layer, and subsequentlyreleasing the tension to thereby increase machine direction elongationand decrease stretch force.
 12. An elastic non-woven laminate fabric,comprising: a) a first and second non-woven fabric web comprised ofthermoplastic polymers, said web having a CD elongation of at least 120%and a basis weight of between about 10-100 gm/m²; b) an elastic filmcomprised of a vinylidene isoprene polymer; said film having a thicknessof between about 0.5 to 3.5 mils; said elastic film attached to saidfirst and second non-woven webs with said film and said web insubstantially relaxed, un-elongated states; and the elastic non-wovenlaminate fabric having a CD elongation of at least 120% with an elasticrecovery of at least 85% after three cycles of 100% elongation; c) saidelastic film being juxtaposed between said first and second nonwoven webin a laminate construction; and d) said laminate construction having adiscontinuous bond pattern of no greater than 15% land area.
 13. Anelastic non-woven laminate fabric as in claim 12, wherein said non-wovenfabric has an elastic CD recovery of at least 90% after three cycles of100% elongation.
 14. An elastic non-woven laminate fabric as in claim12; wherein said non-woven web and the elastic laminate fabric each haveCD elongation of at least 150%.
 15. An elastic non-woven laminate fabricas in claim 12; wherein said elastic film is extrusion coated on saidnon-woven web.
 16. An elastic non-woven laminate fabric as in claim 12,wherein said non-woven web comprises a member chosen from the groupconsisting of spunbond continuous filaments, meltblown continuousfilaments, hydroentangled carded staple fibers, thermally bonded cardedstaple fibers, and adhesively bonded carded staple fibers.
 17. Anelastic non-woven laminate fabric as in claim 12; further comprising asecond non-woven web attached to said film.
 18. An elastic non-wovenlaminate as in claim 17, wherein said second non-woven web is attachedto said film by thermal calendering at a temperature in the meltingrange of said film.
 19. An elastic non-woven laminate fabric as in claim12; wherein said vinylidene isoprene film has a thickness in the rangeof about 2.0 to 2.5 mils.
 20. An elastic non-woven laminate fabric as inclaim 12; wherein said vinylidene isoprene film comprises 70-95% of ablock copolymer with a general formula chosen from the group consistingof: A_(x)-(BA)_(Y)-BA where A is a monovinylidene aromatic monomer, B isa conjugated diene, x is from 0-1, and y is from 0-3; andA-B-R-(B-A)_(n) where A is a monovinylidene aromatic monomer, B is aconjugated diene, R is a remnant of a multifunctional coupling agent,and n is an integer from 1-5.
 21. An elastic non-woven laminate fabricas in claim 12; wherein said non-woven web has a basis weight of about15-50 gm/m².
 22. An elastic non-woven laminate fabric as in claim 12;wherein said laminate fabric further comprises a substantially smoothsurface free of puckers or gathers.
 23. An elastic nonwoven laminatefabric as in claim 12; wherein said laminate fabric is used in theconstruction of protective apparel.
 24. A disposable waste-containmentgarment, comprising; an absorbent core, a liquid pervious topsheet, aliquid impervious backsheet, a number of elastic fitments, one or moreof said elastic fitments comprising an elastic laminate, said elasticlaminate comprising: i) a first and second non-woven fabric webcomprised of thermoplastic polymers, said web having a CD elongation ofat least 120% and a basis weight of between about 10-100 gm/m²; ii) anelastic film comprised of a vinylidene isoprene polymer; said filmhaving a thickness of between about 0.5 to 3.5 mils; said elastic filmattached to said first and second non-woven webs with said film and saidweb in substantially relaxed, un-elongated states; and the elasticnon-woven laminate fabric having a CD elongation of at least 120% withan elastic recovery of at least 85% after three cycles of 100%elongation; iii) said elastic film being juxtaposed between said firstand second nonwoven web in a laminate construction; and iv) saidlaminate construction having a discontinuous bond pattern of no greaterthan 15% land area.
 25. A disposable waste-containment garment as inclaim 24, wherein the garment is a diaper.